FSCUT2000 Laser Cutting Control System User Manual

FSCUT2000
Laser Cutting Control System
User Manual
Shanghai Friendess Electronic Technology Co., Ltd
www.fscut.com
Version 2.18
FSCUT2000 Laser Cutting Control System
Thank you for using our products!
This Manual describes FSCUT2000 laser cutting control system
in details, including system features, installation instructions etc. If
you want to know more about CypCut laser cutting software that can
improve the performance of BCS100 height controller while using
together, please refer to the relevant help documents. For any other
information, please contact us directly.
Please read the Manual carefully before using the BMC1204
controller card and relevant devices, so that you can make better use of
it in future.
Along with continuous updating of product functions, there may
be some differences between that you received and the Manual.
Herein, we apologize for any inconvenience!
The function information and application scheme of the latest
product can be queried and downloaded, when you log on the official
website www.fscut.com.
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FSCUT2000 Laser Cutting Control System
Contents
Thank you for using our products!.................................................................................... 1
Contents ............................................................................................................................ 2
Chapter 1
Product Introduction ................................................................................... 6
1.1 Introduction ............................................................................................................. 6
1.2 System Connection Schematic Diagram ................................................................... 6
1.3 Technical parameters .............................................................................................. 8
1.4 Control card installation .......................................................................................... 8
1.4.1 Installation Steps .............................................................................................. 8
1.4.2 Recovery processing ......................................................................................... 9
Chapter 2
Port Instructions ........................................................................................ 11
2.1 External IO Board instruction ................................................................................ 11
2.2 Signal type ............................................................................................................. 12
2.2.1 Input signals.................................................................................................... 12
2.2.2 Relay output signal.......................................................................................... 13
2.2.3 Mosfet output signal ...................................................................................... 14
2.2.4 Differential output signal................................................................................ 14
2.2.5 Analog output signal....................................................................................... 15
2.2.6 PWM output signal ......................................................................................... 15
2.3 Terminal Instructions............................................................................................. 16
2.3.1 External power source .................................................................................... 16
2.3.2 Servo control interface ................................................................................... 16
2.3.3 The wiring diagram of servo drive control signal ........................................... 17
2.3.4 Origin and limit input...................................................................................... 26
2.3.5 General input .................................................................................................. 27
2.3.6 General output ............................................................................................... 27
2.3.7 Analog output ................................................................................................. 27
2.3.8 PWM output ................................................................................................... 27
2.4 Connection Diagram .............................................................................................. 28
2.5 Laser connection.................................................................................................... 29
2.5.1 YAG laser connection ...................................................................................... 29
2.5.2 CO2 laser connection ...................................................................................... 29
2.5.3 IPG-YLR series wiring diagram ........................................................................ 29
2.5.4 Germany version IPG_YLS series wiring diagram ........................................... 31
FSCUT2000 Laser Cutting Control System
3
2.5.5 America version IPG_YLS series wiring diagram............................................. 32
2.5.6 SPI-500W-R4 wiring diagram .......................................................................... 33
2.5.7 Bowflex MARS Series wiring diagram ............................................................. 34
2.5.8 JK/GSI-FL Series wiring diagram ..................................................................... 35
2.5.9 Rofin fiber laser wiring diagram ..................................................................... 36
2.5.10 Raycus fiber laser wiring diagram ................................................................ 37
2.5.11 Max laser wiring diagram ............................................................................. 38
Chapter 3 Platform Configuration ................................................................................... 39
3.1 Installation and operation ...................................................................................... 39
3.2 Password Input ...................................................................................................... 39
3.3 User interface ........................................................................................................ 40
3.4 Mechanism configuration ...................................................................................... 41
3.5 Return to origin configuration ............................................................................... 42
3.6 Laser configuration ................................................................................................ 43
3.6.1 CO2 laser configuration .................................................................................. 43
3.6.2 IPG laser configuration ................................................................................... 44
3.6.3 Mars/Rofin/Raycus/SPI/GSI/JK laser configuration........................................ 45
3.6.4 Other lasers .................................................................................................... 46
3.7 Height controller configuration ............................................................................. 46
3.7.1 Use BCS100 network height controller .......................................................... 46
3.7.2 Not use BCS100 network height controller .................................................... 46
3.8 Auxiliary gas configuration .................................................................................... 47
3.9 Alarm configuration ............................................................................................... 49
3.9.1 Operating warning .......................................................................................... 49
3.9.2 Dual-drive excessive deviation alarm ............................................................. 49
3.9.3 Emergent stop button .................................................................................... 49
3.9.4 Pressure alarm ................................................................................................ 49
3.9.5 Customized input alarm .................................................................................. 49
3.10 General input ....................................................................................................... 50
3.11 General output .................................................................................................... 52
3.11.1 Output port configuration ............................................................................ 52
3.11.2 Auto lubricate ............................................................................................... 52
3.11.3 Customize the output ................................................................................... 52
3.11.4 Regional output ............................................................................................ 53
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FSCUT2000 Laser Cutting Control System
3.12 Focus control ....................................................................................................... 53
3.13 Optical edge seeking............................................................................................ 54
3.14 Numerical control panel ...................................................................................... 54
Chapter 4 Electrical System Debugging ........................................................................... 56
4.1 Power test.............................................................................................................. 56
4.2 All the hardware signal test ................................................................................... 56
4.3 Basic motion test ................................................................................................... 56
4.4 Cypcut basic functional test .................................................................................. 57
Chapter 5 Motion effect optimization............................................................................. 58
5.1 Infer inertia ratio and machine characteristics ..................................................... 58
5.2 Servo gain adjustment ........................................................................................... 59
5.2.1 Basic requirement .......................................................................................... 59
5.2.2 Panasonic servo gain adjustment ................................................................... 59
5.2.3 Yaskawa servo gain adjustment ...................................................................... 59
5.2.4 DELTA servo debugging experience ................................................................ 60
5.3 Motion Control parameter adjustment................................................................. 61
5.3.1 Motion control parameter introduction ........................................................ 61
5.3.2 Adjust processing acceleration ....................................................................... 61
5.3.3 Adjust move acceleration ............................................................................... 61
5.3.4 Adjust FIR frequency ...................................................................................... 62
5.3.5 Set circle precision and corner precision........................................................ 63
Chapter 6 General Problems............................................................................................ 64
6.1 “Motion control card initialization fails” pops up when open Cypcut .................. 64
6.2 Pulse equivalent setting ........................................................................................ 65
6.3 How to use USB flash disk to upgrade BMC1204 .................................................. 65
6.4 Graphics processing is quite slow or pause ........................................................... 66
6.5 Corner burning ...................................................................................................... 66
6.6 Laser not emitting light.......................................................................................... 66
Chapter 7 Appendix ......................................................................................................... 68
7.1 Scan cutting setting instructions ........................................................................... 68
7.1.1 Function brief introduction ............................................................................ 68
7.1.2 Function description ....................................................................................... 68
7.1.3 Considerations ................................................................................................ 69
7.2 Pitch compensation ............................................................................................... 69
FSCUT2000 Laser Cutting Control System
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7.2.1 Brief introduction of pitch compensation ...................................................... 69
7.2.2 Determine the machine origin ....................................................................... 70
7.2.3 Determine pulse equivalent ........................................................................... 71
7.2.4 Error measurement ........................................................................................ 71
7.2.5 Import error data............................................................................................ 74
7.2.6 Manually input compensation data ............................................................... 75
7.2.7 General problem solving ................................................................................ 76
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FSCUT2000 Laser Cutting Control System
Chapter 1 Product Introduction
1.1 Introduction
FSCUT2000 is a high-performance open loop laser control system developed
independently by Shanghai Friendess Electronic Technology Co., Ltd. It is widely
used in the field of metal and non-metal laser cutting. Because of its outstanding
performance in the field of medium power fiber laser cutting, it is favored by a large
number of high quality customers.
Please read the manual carefully before using the controller and relevant devices.
FSCUT2000 laser cutting control system is composed of standard accessories as
shown below:
Name
Model
Number
Motion control card
BMC1204
1
External IO board
BCL3762
1
Extension wire (with a guard sheet)
C37-40
1
37-pin cable (2metres)
C37-2
1
62-pin cable (2metres)
C62-2
1
Servo cable (1.5metres)
C15-1.5
3
Dongle
Elite-Dog
1
Laser software
CypCut
1
Wireless handheld box
WKB
1
Numerical control panel (Optional)
BCP5045
1
1.2 System Connection Schematic Diagram
BMC1204 card applies PCI interface whose external size is 213mm*112mm. A
control card has two sockets: JP1 is a DB62M socket with matched C62-02 cable
connected to BCL3762 External IO board; JP2 is an external expansion cavel socket,
with C40-37 expansion winding displacement (with a guard sheet) connected to the
back of computer case firstly, and then with C37-02 cable connected to BCL3762
External IO Board.
The system wire is shown as below:
FSCUT2000 Laser Cutting Control System
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BMC1204 Motion
control card
JP1
JP2
C37-40
PCI Slot
Computer
Mainboard
C62-2
BCL3762
External
IO board
C15-1.5
X axis servo drive
C15-1.5
C15-1.5
C37-2
Y1 axis servo drive
Y2 axis servo drive
FSCUT2000 Laser Cutting Control System
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1.3 Technical parameters
Motor control
signal
Motion
control
Motion control
performance
Laser control signal
I/O Function
Work environment
Power requirement
3 axis with high-speed pulse output and maximum
frequency3MHz
3 axis with encoder feedback channel and four times
frequency up to 8MHz
The original point of every axis with limit, servo
alarm special input signal.
The servo performance of every axis, alarm clear
special output signal.
Control cycle is 1ms.
“S” speed-up and speed-down with wave filtering.
Velocity look-ahead, inflection point with intelligent
speed-up and speed-down.
The speed limit of small circular arc, Local curvature
analysis
The smoothing of turning
Output 1 is PWM signal, with dip switch choosing
24V or 5V.
Output 2 is 0~10V analog signal.
12 general inputs.
18 general outputs, thereto, 10 interfaces are relay
outputs, 8 interfaces are mosfet emitter outputs.
Temperature: 0~55℃
humidity: 5%~90%, no condensation
24V,2A
1.4 Control card installation
1.4.1 Installation Steps
Please carefully handle them, and effectively touch grounded
metal parts before touching control card system or inserting/removing
control card, in order to prevent static electricity from damaging motion
control card, and please wear electricity-proof gloves.
(1) Shut down computer, insert control card into PCI slot, and fix control card
and catch screw of expansion winding displacement.
(2) After start the computer, the window of “Driver Software Installation” pops
up; click “Close” button as shown below. If this window does not pop up, it means
control card is not inserted correctly. So please repeat step one
FSCUT2000 Laser Cutting Control System
9
(3) Install CypCut software, while automatically install BMC 1204 card driver
and softdog driver.
(4) Open the device manager to confirm the success of installation. If the
following icon appeared:
It shows that the installation was successful.
1.4.2 Recovery processing
(1) If after starting the computer, the widow of “Found New Hardware Wizard”
does not pop up, or control card cannot be found in device manager, which means
control card is not inserted correctly. Please replace PCI slot or computer, insert and
fix control card, and then reinstall the software.
(2) If there is yellow exclamation mark in the device, please double click
open attribute page and select “details”, as shown below.
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FSCUT2000 Laser Cutting Control System
(3) The first half of “device instance ID” attribute is
, which
means the computer correctly identifies motion control card and software installation
may fail. Please reinstall Cypcut software. If it fails again, please contact our
technician.
(4) The first half of “device instance ID” attribute is not “
”,
which means the computer doesn't identify motion control card successfully. Please
shut down the computer, replace the PCI slot, fix the control card again, and then
reinstall the software.
(5) If step four still fails, control card may have be damaged. Please contact our
technician.
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Chapter 2 Port Instructions
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FSCUT2000 Laser Cutting Control System
2.1 External IO Board instruction
24V COM
X axis
Control
Relay
Y2/W axis
Control
Relay
W- W0 W+
DA1- DA1+ DA2- DA2+ COM COM COM
1 2 3 4
PWM- PWM+
ON
OFF
OUT10
IN6 IN5 IN4
OUT14~16
IN3 IN2 IN1
OUT17~18
O11 O12 O13 O14 O15 O16 O17 O18 COM
OUT11~13
IN9 IN8 IN7
COM COM COM COM COM COM COM COM COM COM COM COM
IN12 IN11 IN10
OUT9
NC NO CON
Relay
10
OUT8
NC NO CON
Relay
9
OUT7
NC NO CON
Relay
8
OUT6
NC NO CON
Relay
7
OUT5
NC NO CON
Relay
6
OUT4
NO CON
Relay
5
OUT3
NO CON
Relay
4
OUT2
NO CON
Relay
3
OUT1
NO CON
Relay
2
NO CON
Relay
1
Y1 axis
Control
Relay
Y- Y0 Y+
COM COM COM COM COM COM
X- X0 X+
BCL3762-V5.0
24V 24V 24V
Power Input Power output
62-pin Interface
37-pin Interface
BCL3762-V5.2 External IO Board is installed by rail and also can be installed
permanently. Its external size is 315mm*107mm with DM62M and DB37M interface
in two sides, corresponding to JP1 and JP2 of BMC1204. C62-2 cable is used to
connect External IO Board DB62 interface with JP1 port on the back of control card.
FSCUT2000 Laser Cutting Control System
12
JP2 interface is linked by C37-40 baffle wire and then is fixed on erection fixture of
computer with bolts. And C37-2 cable is used to connect DB37 socket on External IO
Board.
The three DB15M interfaces on the top left corner are servo control signals,
which are X axis, Y axis and W axis, respectively, from left to right. When being used
as gantry dual drive, W axis is as Y2 axis. When being used as pipe cutting, W axis is
as rotation axis.
High-low terminals on bottom left are respectively limit and origin signal of X
axis and Y axis. High-low terminals on upper right are origin and limit input of W
axis and general input interface, with all the low terminals break-over, as COM
ground, namely 0 V.
The interface on bottom right is 18 general outputs, thereto, 10 outputs as relay
output, 8 outputs as mosfet output. The first 5 ones of the 10 relay outputs only have
normally open contacts and the second 5 outputs have normally open contacts and
normally closed contacts. The 8th mosfet output is 24 V general cathode output.
The three 2--pin terminals over right above are 1 PWM and 2 DA analog signal.
Dip switch:
There is a 4-bit dip switch below the PWM and DA analog signal. Its usage is
shown as below:
The first bit (P1) and second bit (P2) of 4-bit dip switch choose PWM voltage.
P1
P2
Implication
On
Off
PWM voltage is 24V
Off
On
PWM voltage is 5V
The interface P3 and P4 of 4- bit dip switch choose the signal source of PWM.
P3
P4
Implication
On
Off
Off
On
PWM signal is generated by standby PWM
signal
PWM signal is generated by independent PWM
signal
2.2 Signal type
2.2.1 Input signals
Input signals include: limit, origin and general input. The input of BMC1204
card is active low level: support normally open and normally closed mode (The
polarity of input port can be modified by “platform configuration tool” of CypCut
software). When the setting is normally open, input port and 0 V break-over are active;
when the setting is normally closed, disconnection of 0 V is active.
Input port polarity can be modified through the hardware jumper. Now IN10,
IN11 and IN12 input ports support this function. Jumper has two states, ACT_LOW
as shown in the figure, which means low level is active (inputting 0V voltage is
active); ACT_HIGH as shown in the figure, which means high level is active
(inputting 24V voltage is active). Default state is ACT_LOW.
FSCUT2000 Laser Cutting Control System
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ACT_LOW
ACT_HIGH
Typical connection of optoelectronic switch is shown as below, which must use
24V switch of the NPN type (low level is active).
BCL3762
Optoelectronic switch
COM
—
Y-
OUT
C
24V
+
Typical connection of contact switch is shown as below:
BCL3762
Contact Switch
COM
COM
Y+
NO
Typical connection of magnetic switch is shown as below, which must use 24V
switch of the NPN type.
BCL3762
Magnetic Switch
COM
0V
IN6
OUT
24V
V+
2.2.2 Relay output signal
Load capacity of relay output contact on External IO Board is: 240VAC/5A,
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FSCUT2000 Laser Cutting Control System
30VDC/10A. Controllable small power is 220 V alternating load. Please connect
contactor externally if connected with big power load.
The connection of relay output and contactor is shown as below:
BCL3762
Digital
Quantity
Machine
24V
Coil
Power
2.2.3 Mosfet output signal
There are OUT11~OUT18, total 8 outputs, mosfet emitter output on BCL3762V5.0 External IO Board and it can directly drive 24V direct current device. Each
current supply capacity is 500mA. Typical connection is shown as below:
BCL3762
OUT16
24VCurrent
solenoid
valve
COM
2.2.4 Differential output signal
Pulse command state of control driver is “pulse+direction, negative logic”. The
highest pulse frequency: 3MHZ. The pulse mode is shown as below:
Forward
PUL+
DIR+
Backward
FSCUT2000 Laser Cutting Control System
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The output way of differential signal is shown as below :
VCC
PULPUL
PUL+
2.2.5 Analog output signal
There are 2 outputs of 0~10V analog signal in the External IO Board.
0V~+10V
Range of output signal
Maximum output current load
50mA
Maximum output capacitive load
350pF
Input impedance
100KΩ
Maximum bipolar error
+/-50mV
Resolution ratio
10mV
Conversion speed
400us
2.2.6 PWM output signal
BCL3762 External IO Board has 1 PWM pulse width modulating signal which
can be used for controlling average power of fiber laser. PWM signal level is 5 V or
24 V for selection. Duty cycle is 0%~100% and the highest carrier frequency is 50
KHz. The output way of PWM signal is shown as below:
VCC
PWM
Signal
PWM+
PWM-
We strongly recommend that users install PWM+/- signal to a relay output port in
series (Set it to PWM+/- enable signal.), then access to the laser, which can avoid
laser light leakage in modulation mode. Please refer to “2.5 Laser Connection” for
more details. Furthermore, please adjust PWM signal level. 24 V or 5 V level can be
selected through dip switch.
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FSCUT2000 Laser Cutting Control System
2.3 Terminal Instructions
2.3.1 External power source
External power source provide direct current 24 V for BCL3762 External IO
Board. 24 V and COM of power input terminal are connected to 24 V and 0V of power
output interface, respectively.
2.3.2 Servo control interface
The three servo control interfaces on BCL3762 are DB15 two-row bores, and pin
definition is as below:
8
7
6
5
4
3
2
1
15 14 13 12 11 10 9
The signal definition of matched servo cables is shown as below:
15-pin servo control signal Line
Pin
Line color
Signal Name
Pin
Line color
1
Yellow
PUL+
9
Yellow-Black
2
3
4
5
6
7
8
Blue
Black
Orange
Red
Green
Green-Black
Brown
DIR+
A+
B+
Z+
SON
CLR
24V
10
11
12
13
14
15
Blue-Black
White-Black
Orange-Black
Red-Black
Purple
Brown-Black
Signal
Name
PULDIRABZALM
0V
+24V,0V: Supply 24V DC power for servo drive;
SON: The output is servo enable signal when servo on;
ALM: Alarm, receive servo alarm signal;
PUL+, PUL-: Pulse (PULS), differential output signal;
DIR+,DIR-: Direction (DIR), differential output signal;
A+, A-, B+, B-, Z+, Z-: Three phase of encoder, input signal;
The polarity of SON and ALM signal can be modified through hardware jumper.
SON
ALM
ACT_LOW
ACT_LOW
ACT_HIGH
ACT_HIGH
When the SON signal jump to ACT_LOW state, low level is active (inputting
FSCUT2000 Laser Cutting Control System
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0V voltage is active); When the SON signal jump to ACT_HIGH state, high level is
active (inputting 24V voltage is active). Default state is ACT_LOW.
When the ALM signal jump to ACT_LOW state, low level is active (inputting
0V voltage is active); When the ALM signal jump to ACT_HIGH state, high level is
active (inputting 24V voltage is active). Default state is ACT_LOW.
Please refer to “2.3.3 The wiring diagram of servo drive control signal” for
connection of Panasonic, Yaskawa, Mitsubishi and Delta servo drivers.
Please pay attention to the following information when connect servo driver of
other brands:
(1) Please confirm the type of servo driver SON signal you select whether low
level is active or not. (That is, It is ON when connecting with 24V GND.)
(2) Confirm the parameters of servo driver are set as: the type of received pulse
signal is “pulse + direction”
(3) Confirm whether t h e servo driver input terminal has external crash
stopping signal input or not, and which logic the signal is.
(4) Before the trial operation of servo driver, 24 V power must be provided for
External IO Board, for 24 V power servo driver needs is provided by External IO
Board.
(5) If driver still cannot run, confirm that driver parameter is set as not using
“positive & negative input inhibit”.
(6) Connect shielding layer of signal line with servo driver case.
2.3.3 The wiring diagram of servo drive control signal
FSCUT2000 motion control system apply the signal of “Pulse+Direction” to
control servo driver. The firmware of 1204 motion control card will be upgraded after
the software version is upgraded to CypCut6.3.6xx. The pulse sending frequency cap
is increased from the previous 750Kpps to 3Mpps.
Recommend using high-speed differential pulse signal, and setting the pulse
equivalent of servo driver in 1000 ~2000, in order to improve the interpolation
accuracy.
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FSCUT2000 Laser Cutting Control System
The wiring diagram of Panasonic A5 high-speed pulse
DB15 servo control interface of Friendess
Signal Name Pin
MINAS-A servo 50P interface of Panasonic
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
44
45
46
47
PULSH1
PULSH2
SIGNH1
SIGNH2
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
48
49
23
24
OA+
OAOB+
OBOZ+
OZ-
24V
SON
CLR
ALM
0V
8
6
7
14
15
7
COM+
29 SRV-ON
31 A-CLR
37 ALM+
41 COM36 ALM-
The wiring diagram of Panasonic A5 low-speed pulse
DB15 servo control interface of Friendess
Signal Name Pin
MINAS-A servo 50P interface of Yaskawa
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
3
4
5
6
PULS1
PULS2
SIGN1
SIGN2
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
48
49
23
24
OA+
OAOB+
OBOZ+
OZ-
24V
SON
CLR
ALM
0V
8
6
7
14
15
7
COM+
29 SRV-ON
31 A-CLR
37 ALM+
41 COM36 ALM-
FSCUT2000 Laser Cutting Control System
19
Basic setting parameters of Panasonic A5 series
Parameter Recommended
Implication
Type
value
Pr001
0
Control mode must be set as location mode.
Pr007
3
Have to select “Pulse+Direction” mode
When using high-speed pulse connection mode,
this parameter is set as 1, and the maximum
supported pulse frequency is 3Mpps;
Pr005
1
When using low-speed pulse connection mode,
this parameter is set as 0, and the maximum
supported pulse frequency is 500Kpps;
The wiring diagram of Yaskawa servo
∑ series servo 50P interface of Panasonic
DB15 servo control interface of Friendess
Signal Name Pin
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
7 PULS
8 *PULS
11 SIGN
12 *SIGN
A+
AB+
BZ+
Z-
3
11
4
12
5
13
33
34
35
36
19
20
24V
SON
CLR
ALM
0V
8
6
7
14
15
47 +24V IN
40 /S-ON
44 /ALM-RST
31 ALM+
1
SG
32 ALM-
PAO
*PAO
PBO
*PBO
PCO
*PCO
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FSCUT2000 Laser Cutting Control System
Basic setting parameters of Yaskawa Σ series
Parameter Recommended
Implication
Type
value
Pn000
001X
Set as location mode
When the input is single-phase power, modify
Pn00B
No
into 0100
Positive logic: pulse + direction; 0005H
negative logic: Pulse + direction
When the pulse frequency is lower than
Pn200
2000H
1Mpps, please select 0000H mode;
When the pulse frequency is up to 1Mpps ~
4Mpps, please select 2000H mode.
Pn50A
8100
Can be driven in co-rotation side
Pn50B
6548
Can be driven in reverse side
The high-speed pulse wiring diagram of Delta A series
DB15 servo control interface of Friendess
Signal Name Pin
ASD-A servo 50P interface of Delta
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
38 HPULSE
29 /HPULSE
46 HSIGN
40 /HSIGN
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
25
23
50
24
OA
/OA
OB
/OB
OZ
/OZ
24V
SON
CLR
ALM
0V
8
6
7
14
15
11
9
33
28
45
27
COM+
DI1 SON
DI5 ARST
DO5+ ALRM
COMDO5-
FSCUT2000 Laser Cutting Control System
The low-speed pulse wiring diagram of Delta A series
DB15 servo control interface of Friendess
Signal Name Pin
ASD-A servo 50P interface of Delta
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
43 PULSE
41 /PULSE
36 SIGN
37 /SIGN
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
25
23
50
24
OA
/OA
OB
/OB
OZ
/OZ
24V
SON
CLR
ALM
0V
8
6
7
14
15
11
9
33
28
45
27
COM+
DI1 SON
DI5 ARST
DO5+ ALRM
COMDO5-
Basic setting parameters of Delta A series
Paramete Recommended
Implication
r Type
value
Control mode, position control mode Negative
logic pulse + direction.
Set parameters as: 1102H start the high speed
P1-00
1102H
differential signal, the maximum pulse
frequency is 4Mpps;
Set the parameters as: 0102H is low-speed pulse
signal, the maximum pulse frequency is 500K.
Select a position mode of external command
P1-01
00
control
DI1 is set a SON servo enabling, logic is
P2-10
101
normally open.
DI5 is set as ARST clear alarm function, logic is
P2-14
102
normally open.
DO5 is set as ALRM Servo alarm function,
P2-22
007
logic is normally closed.
21
22
FSCUT2000 Laser Cutting Control System
The servo wiring diagram of Sanyo R series
DB15 servo control interface of Friendess
Signal Name Pin
Gr8.11
Gr9.00
Gr9.01
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
26
27
28
29
F-PC
F-PC
R-PC
R-PC
A+
AB+
BZ+
Z-
3
11
4
12
5
13
3
4
5
6
7
8
AO+
AOBO+
BOZ0+
ZO-
8
6
7
14
15
49 OUT-PWR
50 CONTCOM
37
CONT1
15
CONT8
46
OUT8
24 OUT-COM
24V
SON
CLR
ALM
0V
Parameter
Type
SY08
R series servo 50P interface of Sanyo
Basic setting parameters of Sanyo R series
Recommended
Implication
value
00
Set as position mode
Select pulse signal input type: Pulse +
02
direction;
00
Can be driven in co-rotation side
00
Can be driven in reverse side
FSCUT2000 Laser Cutting Control System
The wiring diagram of Schneider 23A high-speed pulse
DB15 servo control interface of Friendess
Signal Name Pin
23A-50P interface of Schneider
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
38 HPULSE
29 /HPULSE
46 HSIGN
40 /HSIGN
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
23
25
50
24
OA
/OA
OB
/OB
OZ
/OZ
24V
SON
CLR
ALM
0V
8
6
7
14
15
11
9
33
7
49
6
COM+
DI1DI5DO1+
COMDO1-
The wiring diagram of Schneider 23A low-speed pulse
DB15 servo control interface of Friendess
Signal Name Pin
23A-50P interface of Schneider
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
41 PULSE
43 /PULSE
37 SIGN
36 /SIGN
A+
AB+
BZ+
Z-
3
11
4
12
5
13
21
22
23
25
50
24
OA
/OA
OB
/OB
OZ
/OZ
24V
SON
CLR
ALM
0V
8
6
7
14
15
11
9
33
7
49
6
COM+
DI1DI5DO1+
COMDO1-
23
24
FSCUT2000 Laser Cutting Control System
Basic setting parameters of Schneider Lexium 23D series
Parameter
Recommended
Implication
Type
value
Control mode, position control mode
Negative logic pulse + direction.
Set parameters as: 1102H starts the high
speed differential signal, the maximum pulse
P1-00
1102H
frequency is 4Mpps;
Set the parameters as: 0102H is low-speed
pulse signal, the maximum pulse frequency
is 500K.
Set as: position mode of external signal
P1-01
X00
control
P2-10
101
IN1 of servo is modified to SON function.
P2-11
0
No using IN2
P2-13~P2-17
0
No using IN4~IN8
The wiring diagram of Fuji A5 series
DB15 servo control interface of Friendess
Signal Name Pin
A5-26P interface of Fuji
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
7
8
20
21
CA
*CA
CB
*CB
A+
AB+
BZ+
Z-
3
11
4
12
5
13
9
10
11
12
23
24
FFA
*FFA
FFB
*FFB
FFZ
*FFZ
24V
SON
CLR
ALM
0V
8
6
7
14
15
1
COMIN
2
CONT1
3
CONT2
17 OUT3
14 COMOUT
FSCUT2000 Laser Cutting Control System
Fuji ALPHA 5 series
Parameter
Recommended
Type
value
PA-101
0
PA-103
0
25
Implication
Position control mode
Pulse + direction, the highest frequency is
1Mpps
The wiring diagram of Mitsubishi J3 Series
DB15 servo control interface of Friendess
Signal Name Pin
MR-J3-A servo 50P interface of Mitsubishi
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
10
11
35
36
PP
PG
NP
NG
A+
AB+
BZ+
Z-
3
11
4
12
5
13
4
5
6
7
8
9
LA
LAR
LB
LBR
LZ
LZR
24V
SON
CLR
ALM
0V
8
6
7
14
15
20
15
19
48
46
DICOM
SON
RES
ALM
DOCOM
26
FSCUT2000 Laser Cutting Control System
The wiring diagram of Mitsubishi E Series
DB15 servo control interface of Friendess
Signal Name Pin
MR-E-A servo 26P interface of Mitsubishi
Shielded wire
Pin
Signal Name
PUL+
PULDIR+
DIR-
1
9
2
10
23
22
25
24
PP
PG
NP
NG
A+
AB+
BZ+
Z-
3
11
4
12
5
13
15
16
17
18
19
20
LA
LAR
LB
LBR
LZ
LZR
2
OPC
1
4
3
9
13
8
VIN
SON
RES
ALM
SG
EMG
24V
SON
CLR
ALM
0V
8
6
7
14
15
Basic setting parameters of Mitsubishi MR-J3 - A series
Paramete Recommended
Implication
r Type
value
PA01
0
Control mode-Position mode
PA13
0011
Negative logic: Pulse+Direction
The maximum pulse frequency of Mitsubishi J3 series is 1Mpps.
Note:
Parameter settings above can guarantee basic sports only under the
circumstances of the right wiring connection, not ensure control precision. And if you
need to further optimize campaign results, please adjust the rigidity, gain, inertia ratio
and other parameters.
2.3.4 Origin and limit input
X-: the limit of minus X direction, dedicated input signal and low level is active;
X0: the origin signal, dedicated input signal and low level is active;
X+: the limit of positive X direction, dedicated input signal and low level
is active;
COM: GND, the general interface of the above three signals;
Y-: the limit of minus Y direction, dedicated input signal and low level is active;
Y0: the origin signal, dedicated input signal and low level is active;
Y+: the limit of positive Y direction, dedicated input signal and low level
is active;
FSCUT2000 Laser Cutting Control System
27
COM: GND, the general interface of the above three signals;
W-: the limit of minus W direction, dedicated input signal and low level is active;
W0: the origin signal, dedicated input signal and low level is active;
W+: the limit of positive W direction, dedicated input signal and low level is
active;
COM: GND, the general interface of the above three signals;
The input logic of limit and origin signal can be modified through “platform
configuration tool” coming with the CypCut software. Please refer to chapter 3
platform configuration tool for more details.
2.3.5 General input
There are 12 general inputs with IN1~IN12. 12 general inputs can be configured
as various custom buttons or alarm input through “platform configuration tool”
coming with the C y p C u t software. Please refer to chapter 3 platform
configuration tool for more details.
2.3.6 General output
There are 10 relay outputs with OUT1~OUT10. 10 r e l a y outputs c a n b e
configured as the control port corresponding to “laser”, “auxiliary gas”, “height
controller”, “indicator light” through “platform configuration tool” coming with the
CypCut software. Please refer to chapter 3 platform configuration tool for more
details.
When BCL3762-V5.0 External IO Board is selected, besides 10 relay outputs,
there are also 8 mosfet outputs, which can directly drive 24V direct current device.
2.3.7 Analog output
DA1 and DA2 are 2 outputs of 0~10V analog signal. DA1 and DA2 can be
configured as a control signal of controlling the laser peak power and proportional
valve through “platform configuration tool” coming with the CypCut software.
2.3.8 PWM output
When the laser type is configured as “fiber laser” through “platform
configuration tool” coming with the software, PWM output port will be activated
and used for controlling fiber laser average power.
When PWM is controlled needing to use 5V, 1 pin of four bit dip switch is OFF,
and 2 pin of four-bit dip switch is ON; Optionally select one among 3 pin and 4 pin is
ON, then another one is OFF.
When PWM is controlled needing to use 24V, 1 pin of four bit dip switch is ON,
and 2 pin of four bit dip switch is OFF; Optionally select one among 3 pin and 4 pin is
ON, then another one is OFF.
FSCUT2000 Laser Cutting Control System
28
2.4 Connection Diagram
DB62-pin Socket
24V
Power Input
X+limit
Y-limit
Y+limit
X axis
servo
interface
Control
Relay
YY0
Y+
COM
Customized
Output
Y axis
servo
interface
Normally
Open
Contact
OUT5
OUT6
Relay
Output
Normally
Open&Closed
Contact
PWM
Output
PWMPWM+
Analog
Output1
DA1DA1+
Analog
Output2
DA2DA2+
OUT10
OUT11
DC
24v
Output
Thyristor
Output
OUT18
COM
DB37-pin Socket
Y axis
Servo
DB15-pin
Socket
W axis
servo
interface
OUT1
DB15-pin
Socket
Y origin
XX0
X+
COM
X axis
Servo
DB15-pin
Socket
X-limit
X origin
+24V
COM
IN12
IN11
IN10
IN9
IN8
IN7
IN6
IN5
IN4
IN3
IN2
IN1
COM
W axis
Servo
Laser
Modulating
Signal
GND
Voltage
GND
Voltage
Laser
Proportional
Valve
Customized
Input
FSCUT2000 Laser Cutting Control System
29
2.5 Laser connection
2.5.1 YAG laser connection
Directly connect output port whose configuration is laser output signal to laser,
which will not be covered here.
2.5.2 CO2 laser connection
Herein, Nanjing Optical Valley Nuotai NT-2000SM CO2 FAF laser is included as
an example, and lasers of other brands are similar
BCL3762_V5.0 external IO board
Analog output
24P plug of Nuotai NT-2000SM CO2 FAF laser
DA1DA1+
6
OUT11
Configure OUT13 as laser form1 OUT13
10
Electrical shutter
8
EP Intense Pulse
OUT14
9
SP Intense Pulse
COM
19
Switch 0V
NO
CON
11
Mechanical shutter
12
Mechanical shutter
(Select DA1 to control laser power)
7
Laser power
Analog 0V
Thyristor output
(Configure OUT11 as electric shutter
Configure OUT14 as laser form2)
Any relay output
(To be configured as a
mechanical Optical shutter)
)
Note: The mechanical
shutter response
signals Cannot be
connected, then set
the input port of
response input as 0.
Any input port
(To be configured as a mechanical
shutter response input)
IN
16
Mechanical Shutter
response
COM
18
Passive contactor CON
Note:
Part of the CO2 laser also supports PWM control mode, and specific wiring
connection can refer to ChuangXin laser wiring diagram.
2.5.3 IPG-YLR series wiring diagram
FSCUT2000 Laser Cutting Control System
30
25P air plug of IPG_YLR series laser
ComputerRS232 DB9
1
2
3
4
Interlock Ch1
5
6
7
RS232 Rx
RS232 Tx
RS232 COM
15
modulation+
modulation-
Interlock Ch2
Interlock Ch2
Interlock Ch1
1
6
7
8
9
2
3
4
5
BCL3762_V5.2 external IO board
Dip switch
ON
PWM
output
PWMPWM+
1 2 3 4
Any relay output
(To be configured as PWM
enable +)
NO
CON
Any relay output
(To be configured as PWM
Enable -)
NO
CON
Any relay output
(To be configured as a
remote start button
signal output port)
NO
CON
16
Remote start button
cannot be connected,
generally do not
recommend customers
use the remote start
button.
10 Rem start button
11 Rem start button
When the laser you are using supports serial or Ethernet communications control,
we strongly recommend that you connect communication ports (serial or network
interface). Using serial or Ethernet communication, CypCut software will monitor
laser status in real-time, and can operate lasers by means of communication.
Implementation including switch shutter (Emission), switch red (Guide beam), set the
peak power (Current) and other actions, no longer need to connect the analog
interface to control the laser peak power.
Recommended network interface of IPG-YLR series.
Notes
1. remote start button cannot be connected, especially when the laser is not in a
good grounding , we do not recommend users to add remote start button, which is
easy to cause the laser to produce failure.
2. PWM select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally
select one among 3 pin and 4 pin is ON, then another one is OFF.
FSCUT2000 Laser Cutting Control System
31
2.5.4 Germany version IPG_YLS series wiring diagram
IPG Germany version YLS series laser
64Pin interface XP1
BCL3762_V5.2 external IO board
Thyrister output
(Configure OUT11 as Laser ON
Configure OUT12 as Laser Request
Configure OUT13 as Program Start
Configure OUT14 as Red light switch)
Power
output
OUT11
OUT12
OUT13
OUT14
C1
Laser ON
A1
A2
Laser Request
Program Start
A5
Guide Laser On
COM
A16
Common
+24V
A6
+24V
COM
B15
24V
B16
0V
Anolog Control ON
24V Relay
General input
(To be configured as
Emission Status)
IN
B2
COM
25Pin interface XP2
Dip switch
ON
Emission ON
PWM output
1 2 3 4
Any relay output
(To be configured as PWM
Enable +)
Any relay output
(To be configured as PWM
Enable -)
PWMPWM+
A1
A2
NO
CON
NO
CON
modulation+
modulation-
C1 Interlock Ch1
C2 Interlock Ch2
C3 Interlock Ch2
C4 Interlock Ch1
7Pin interface XP4
Analog output
(Select DA1 to control
laser power)
DA1DA1+
A1
A2
0~10V
AGND
Note:
1. B2 pin of XP1 interface cannot connect Emission ON, then make sure that the
Emission Status input port is set as 0 in "platform configuration tool", which means
do not detect whether the shutter has been open or not.
2. PWM select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally select
one among 3 pin and 4 pin is ON, then another one is OFF.
FSCUT2000 Laser Cutting Control System
32
2.5.5 America version IPG_YLS series wiring diagram
BCL3762_V5.2 external IO board
IPG American version YLS series laser
64Pin interface XP1
Thyrister output
( Configure OUT11 as Laser Request
Configure OUT12 as Program Start
Configure OUT13 as Red light switch)
Power output
General input
(To be configured as
Emission Status)
OUT11
OUT12
A1
A2
Laser Request
Program Start
OUT13
COM
A5
Guide Laser On
A16
Common
+24V
A6
+24V
COM
B15
24V
B16
0V
24V Relay
IN
B2
1 2 3 4
Emission ON
COM
25Pin Interface XP2
Dip switch
ON
Anolog Control ON
PWM
output
Any relay output
(To be configured as PWM
Enable +)
Any relay output
(To be configured as PWM
Enable -)
Any relay output
(To be configured as Laser
on)
PWMPWM+
NO
CON
NO
CON
NO
CON
A1
modulation+
A2
modulation-
A8
A9
Remote Mode
Remote Mode
C1
C2
Interlock Ch1
C3
C4
Interlock Ch2
C5
C6
Interlock Ch2
Interlock Ch1
Power On
Power On
7Pin interface XP4
Analog output
(Select DA1 to control
laser power)
DA1DA1+
A1
A2
0~10V
AGND
Note:
B2 pin of XP1 interface cannot connect Emission ON, then make sure that the
Emission Status input port is set as 0 in "platform configuration tool", which means
do not detect whether the shutter has been open or not.
PWM select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally
select one among 3 pin and 4 pin is ON, then another one is OFF.
FSCUT2000 Laser Cutting Control System
33
2.5.6 SPI-500W-R4 wiring diagram
SPI-500W R4 Laser Systems
InterLock
1
2
4
5
Computer RS232 DB9
8
9
Interlock Ch2
Interlock Ch2
Interlock Ch1
RS232 Comms Port
1
6
7
Interlock Ch1
2
3
4
2
3
5
RS232 Rx
RS232 Tx
RS232 COM
5
BCL3762_V5.2 external IO board
Mod Input TTL
Dip switch
ON
1 2 3 4
PWM
output
Any relay output
(To be configured as PWM
enable +)
Any relay output
(To be configured as PWM
enable -)
PWMPWM+
modulation+
modulation-
NO
CON
NO
CON
Note:
1. When the modulation signal select MODINPUTTTL interface, PWM select
5V control (Dip switch: 1 pin is OFF, 2 pin is ON;Optionally select one among 3
pin and 4 pin is ON, then another one is OFF.
2. When the modulation signal select 1 pin of I / O interface, PWM select 24V
control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally select one among 3 pin
and 4 pin is ON, then another one is OFF.
FSCUT2000 Laser Cutting Control System
34
2.5.7 Bowflex MARS Series wiring diagram
MARS-500W Laser Systems
Computer RS232 DB9
D-SUB 9
1
6
7
8
9
2
3
4
2
3
5
RS232 Rx
RS232 Tx
RS232 COM
5
BCL3762_V5.2 external IO board
D-SUB 15
Dip switch
ON
1 2 3 4
PWM
output
Any relay output
(To be configured as PWM
enable +)
Any relay output
(To be configured as PWM
enable -)
PWMPWM+
NO
CON
3
6
modulation+
modulation-
8
+5v
INTLK
9
NO
CON
Note:
PWM of Bowflex laser select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;
Optionally select one among 3 pin and 4 pin is ON, then another one is OFF.)
FSCUT2000 Laser Cutting Control System
35
2.5.8 JK/GSI-FL Series wiring diagram
JK/GSI-500W-FL
SK11
Computer RS232 DB9
PL1
1
6
7
8
9
2
3
4
2 RS232 Tx
3 RS232 Rx
5 RS232 COM
5
1
2
5
6
7
15
14
13
10
9
Cus Interlock 1
Cus Interlock 2
Bench interlock 1
Bench interlock 2
Cooling Interlock
Cooling Interlock
Bench interlock 2
Bench interlock 1
Cus Interlock 2
Cus Interlock 1
BCL3762_V5.2 external IO board
SK101
PWM
output
PWMPWM+
modulation+
modulation-
NO
CON
Any relay output
(To be configured as PWM
Enable -)
NO
CON
Note:
1. Several wires on SK11 which need to be interlocked, can connect the
appropriate equipment to ensure safety interlock in accordance with the corresponding
interpretation.
2. When the modulation signal select SK101 interface, PWM select 5V control
(Dip switch: 1 pin is OFF, 2 pin is ON;Optionally select one among 3 pin and 4 pin
is ON, then another one is OFF.
3. When the modulation signal select 16 pin of PL5 interface, PWM select 24V
control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally select one among 3 pin
and 4 pin is ON, then another one is OFF.)
FSCUT2000 Laser Cutting Control System
36
2.5.9 Rofin fiber laser wiring diagram
Rofin fiber laser
X710 interface
BCL3762_V5.2 external IO board
Thyristor output
(Configure OUT11 as Mission ON
Configure OUT12 as Fault Reset
Configure OUT13 as Stand By
OUT11
OUT12
OUT13
Configure OUT14 as Red light switch
OUT14
Configure OUT15 as Gate)
OUT15
COM
Dip switch
ON
1 2 3 4
PWM
output
Any relay output
(To be configured as PWM
Enable +)
Any relay output
(To be configured as PWM
Enable -)
PWMPWM+
3
1
Mains on
Program Start
4
8
10
9
13
Stand By
Guide Laser On
Gate
Ext GND
15
16
Ext Pulse 5V
Ext Pulse GND
Gate GND
NO
CON
NO
CON
X720 interface
22
Interlock Ch1
23
Interlock Ch1
24
25
Interlock Ch1
26
27
Interlock Ch1
28
29
Interlock Ch1
30
31
32
33
Interlock Ch1
Interlock Ch1
Interlock Ch1
Interlock Ch1
Interlock Ch1
Interlock Ch1
Interlock Ch1
X704 interface
Analog Output
(Select DA1 To control
the laser power)
DA1DA1+
1
14
Analog+
Analog-
Note:
1. Several wires on SK11 which need to be interlocked, can connect the
appropriate equipment to ensure safety interlock in accordance with the corresponding
interpretation.
2. PWM of Rofin laser select 5V control (Dip switch: 1 pin is OFF, 2 pin is ON;
Optionally select one among 3 pin and 4 pin is ON, then another one is OFF.)
FSCUT2000 Laser Cutting Control System
37
2.5.10 Raycus fiber laser wiring diagram
RayCus fiberlaser
InterLock
b
c
Interlock Ch1
Interlock Ch1
Computer RS232 DB9
COMMAND RS232
1
6
7
8
9
2
3
4
2
3
5
RS232 Rx
RS232 Tx
RS232 COM
5
BCL3762_V5.2 external IO board
PWM
output
PWMPWM+
Any relay output
(To be configured as PWM
enable +)
NO
CON
Any relay output
(To be configured as PWM
enable -)
NO
CON
INPUT MOD
modulation+
modulation-
Note:
1. Raycus new lasers need to use 24VPWM signal control, while the old ones use
5V PWM signal. And new lasers can use the serial port control only before the key
switch is in the REM state, while key switch of the old ones is in the ON state. It will
indicate whether the laser is 24V PWM interface control or not; when it’s not
indicated or marked with 5V, 5V control mode can be applied totally.
2. PWM select 5V control (Dip switch: 1 pin is OFF, 2 pin is ON;Optionally
select one among 3 pin and 4 pin is ON, then another one is OFF.)
3. PWM select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;Optionally
select one among 3 pin and 4 pin is ON, then another one is OFF.)
FSCUT2000 Laser Cutting Control System
38
2.5.11 Max laser wiring diagram
Max fiber laser
InterLock
1
19
BCL3762_V5.2 external IO board
Max laser interface
Dip switch
ON
1 2 3 4
Water Chiller safety
interlock
Water Chiller safety
interlock
PWM
output
PWMPWM+
Any relay output
(To be configured as PWM
enable +)
NO
CON
Any relay output
(To be configured as PWM
enable -)
NO
CON
15
modulation+
3
modulation-
OUT17
OUT18
COM
17
Redlight+
16 Emission enable+
21 Emission enableRed light22
Analog output
(Select DA1 to control
laser power)
DA1DA1+
5
12
AGND
0~10V
Any input port
(To be configured as a laser
alarm)
IN
18
23
PD+
PD-
Any thyristor output
(To be configured to enable
light
and red light)
COM
Note:
1. PD+PD- is a laser alarm output, connected to the input of BCL3762 External
IO Board any interface, and with setting a custom laser warning (normally open) in
"Platform Configuration - Alarm - Custom Alarm".
2. Red and Laser On enable GND can be incorporated together into any COM
port of BCL3762.
3. PWM of Max laser select 24V control (Dip switch: 1 pin is ON, 2 pin is OFF;
Optionally select one among 3 pin and 4 pin is ON, then another one is OFF.)
FSCUT2000 Laser Cutting Control System
39
Chapter 3 Platform Configuration
3.1 Installation and operation
When you install CypCut software, your default selection is platform
configuration tool.
Click “start”- “all programs”- “CypCut software for laser cutting”- “platform
configuration tool” (the icon is
) to operate platform configuration tool software.
“CypCut software for laser cutting” in the path is the name of software. Different
customers have different software names.
3.2 Password Input
Before operate platform configuration tool, password box will appear as
shown below:
Input password 61259023 and click “OK”, and you can start configuration of
platform parameters.
Notes:
users should do parameter configuration based on actual configuration of cutting
platform and wrong configuration may lead to unpredictable consequence! In the
platform configuration, the orange background color represents the input port
configuration, the green background color represents the output port configuration.
40
FSCUT2000 Laser Cutting Control System
3.3 User interface
Main interface of platform configuration tool is information overview; The left
and the upper convenient buttons are for entering various parameters setting page;
green selected box as shown in the figure above is convenient button for
controlling laser, height controller and adjusting auxiliary gas. Click left “config file”
button to locate Data file.
Double click information overview to enter into parameters setting page for
current information, such as: double click “mechanism” to enter machine setting page.
Click “Load” button to open existing configuration files; Click “Save” button to
save information.
Notes:
1. Data files include various configuration information of CypCut software.
2. Data files backup function is in CypCut software ---- "File" ---- "parameter
backup".
FSCUT2000 Laser Cutting Control System
41
3.4 Mechanism configuration
Select drive mode for Y axis (single drive or double drive), based on
mechanical structure, and then configure information of rotation axis.
X axis range: Width of rectangle on CypCut painting interface. After start
software limit protection, max motion range for X axis.
Y axis range: Height of rectangle on CypCut painting interface. After start
software limit protection, max motion range for Y axis.
Pulse equivalent: Pulse count sent for 1 mm motion. Count automatically
by actual motion distance and pulse count, and millimeter value can be set as four
digits after the decimal point. Pulse equivalent= pulse count/ millimeter value.
Servo alarm: Select servo alarm signal logic, or close servo alarm feedback.
Speed limit: limit max speed and acceleration for CypCut software.
Pitch Compensation: Error compensation for Interferometer data.
Verticality correction: When installation of X axis and Y axis is not 90o, the
deviation can be eliminated through “Verticality correction”.
42
FSCUT2000 Laser Cutting Control System
3.5 Return to origin configuration
Forced open software limit: Enforce to open software limit function, and
prevent users from manually switching the software limit in the master interface of
CypCut.
Prompt user to return to origin after booting: Prompt the user to do the
operation of returning to the origin each time you open the software.
ORG direction: Different type can select different rollback to origin direction.
Back to origin direction determines which quadrant tool coordinate is in. For
example, if X axis and Y axis select negative back to the origin, tool motion is in the
first quadrant.
ORG signal: if users select limitation signal, origin switch can be replaced by
limitation switch in the process of back to origin to realize coarse positioning.
Z direction signal: whether to use Z direction signal and sampled signal
determines specific process of back to origin. The system will show a whole process
on an image based on different back to origin way.
Fine speed: As shown in the green section of the figure, approach the origin
slowly and 10mm/s is recommended.
Coarse speed: As shown in the blue section of the figure, approach the origin
fast and 10mm/s is recommended.
Rollback distance: A distance for back in the motions of back to origin can
ensure distance of mechanical origin leaving a distance from position limit switch.
Limit switch logic: Set logic of X, Y, Z axis limit, and origin signal.
FSCUT2000 Laser Cutting Control System
43
3.6 Laser configuration
CypCut provides different lasers configuration for YAG, CO2, IPG, Raycus, and
SPI, other fibers, and different fiber types correspond to different parameters.
3.6.1 CO2 laser configuration
Mechanical shutter: Set output port for controlling mechanical shutter.
Electrical shutter: Set output port for controlling electrical shutter.
Response input: Set output port for response signal after opening mechanical
shutter.
Laser Model: Set laser form as continuous wave, gate pulse and strong pulse
through laser model 1 and laser model 2.
DA Select: 1204 card provides 2 interfaces of analog quantity and any
interface o f output power controlling laser.
DA Range: Set analog quantity range of controlling laser power.
Minimum Power: Set minimum limit for pulse power.
44
FSCUT2000 Laser Cutting Control System
3.6.2 IPG laser configuration
PWM enable signal: Select a relay output port as PWM enable switch, which
can avoid laser leakage or wrong trigger under modulation mode.
DA Select: 1204 card provides 2 interfaces of analog quantity. Any interface
can control laser peak power. Don’t use this port when using serial port or
n e t w o r k remote control.
IPG fiber laser configuration: Remote start button:
After starting IPG remote control, CypCut software will monitor the state of
lasers in real time and can operate lasers by means of communication. Motions, such
as Emission, Guide beam, Current, etc, are realized. After selecting this option, DA
port will be not available.
IPG remote control provides serial port and network, so users can set serial
port or network IP address based on actual condition. If communication of PC, laser
and BCS 100 applies network communication, please pay attention to don’t repeat
segment. For example, if height controller segment is 10.1.1.x, and then laser can
be set as 192.168.1.x. From the perspective of system stability, network is
recommended. If using serial port communication, please pay attention to shell and
shielding layer of serial port connector must be ground connection.
FSCUT2000 Laser Cutting Control System
45
3.6.3 Mars/Rofin/Raycus/SPI/GSI/JK laser configuration
Except remote control, the configuration of Mars, Raycus and SPI fiber laser is
the same as IPG fiber laser, and supports serial port communication.
Debug mode: After opening this mode, CypCut run record column shows the
code of communication between the software and lasers.
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FSCUT2000 Laser Cutting Control System
3.6.4 Other lasers
Laser On Enable: Correspond to the shutter button on software, this signal can
open shutter of the laser.
3.7 Height controller configuration
3.7.1 Use BCS100 network height controller
If use network height controller matched by our company (Abbreviation as
BCS100), please set IP address which should be s the same as the network address
in the BCS 100 parameters.
IP address setting, please refer to instructions P2.5.6 of BCS100 for more detail.
3.7.2 Not use BCS100 network height controller
FSCUT2000 Laser Cutting Control System
47
CypCut also supports input/output port to control height controller of other
brands. Users can set the output port of following, rise (close following), stop (Hold),
move up and down by clicking, and input port of following signal, by themselves.
Follow: open the input port for following.
Retract: set output port for raising (close following).
Stop/ Hold: Set output port for stopping Z axis motion.
Jog up: Set output port for manually controlling Z axis raising.
Jog down: Set output port for manually controlling Z axis declining.
Tracking in place signal: Set input port for collecting and following signal.
Tracking in place signal level: Set effective mode for controlling signal level.
Notes: If port is set as “0”, it means it is not available. If there is no this signal,
please don’t set randomly, otherwise it may cause logical error!
3.8 Auxiliary gas configuration
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FSCUT2000 Laser Cutting Control System
High pressure valve and low pressure valve: Set the total output port for
auxiliary gas correspond to switch.
Air Port: Set output port for air selection.
O2 Port: Set output port for oxygen selection.
N2 Port: Set output port for nitrogen selection.
Users can select two interfaces of analog of 1204 card to regulate auxiliary gas
pressure.
If select “use high pressure valve, low pressure valve to regulate air”, users can
set input port and name of high pressure valve and low pressure valve.
FSCUT2000 Laser Cutting Control System
49
3.9 Alarm configuration
3.9.1 Operating warning
When the machine operates, the title bar will display a yellow warning message.
You can customize the display.
3.9.2 Dual-drive excessive deviation alarm
If X or Y axis of the platform structure apply a bilateral drive, you can set up a
dual-drive shaft position excessive deviation alarm. If the dual-drive error reaches a
certain value (allowable deviation) and continues for a certain period of time (duration
time), the system will generate a "dual-drive shaft position excessive deviation alarm".
If the deviation reached the maximum deviation value (maximum deviation) in a
moment, the system will immediately generate an alarm.
3.9.3 Emergent stop button
Configure input port for emergent stop button, and here emergent stop is an input
signal. If input port is active, emergent stop alarm will be generated.
3.9.4 Pressure alarm
Configure input port for pressure alarm, and here alarm is an input signal. If
input port is active, pressure alarm will be generated.
3.9.5 Customized input alarm
Users can add other types of alarm in “customized input alarm” and input alarm
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FSCUT2000 Laser Cutting Control System
name in alarm description. Select port number and level detection type corresponding
to alarm. General customized alarms include lack-voltage alarm, excessive
temperature alarm, laser head collision alarm, etc.
Notes: All the alarm states will be automatically eliminated within 2 seconds
after eliminating alarm signal.
3.10 General input
Click on the "Function Select" button, users can select the function name of the
input port in the drop-down list, and then configure the corresponding input port and
level detection.
Some functions of switching are divided into four sub-items, such as a laser
switch, as shown below:
FSCUT2000 Laser Cutting Control System
Each instruction is shown as below, please select according to your needs.
It’s in the following table.
Function Name
Instructions
Laser on (press on, loosen
off)
Press the button: Open the corresponding
function; Loosen the button: Not perform any
action.
Laser off (press off, loosen
invariant)
Press the button: Close the corresponding
function; Loosen the button: Not perform any
action.
Laser on/off (switch)
Press the button: Open the corresponding
function; Loosen the button: close the function.
Laser on/off (Lock)
Press the button: open the corresponding
function; press again: close the function.
51
52
FSCUT2000 Laser Cutting Control System
3.11 General output
3.11.1 Output port configuration
Guide: Set output port for beam switch.
Work instructions: After port configuration, corresponding indicator light will
blink when processing.
Alarm light: After port configuration, corresponding indicator light will blink
during alarming.
Laser instructions: After port configuration, corresponding indicator light will
blink during lightening.
Alarm tone: After port configuration, corresponding bell will ring during
alarming.
Light flashing: After this series function is enabled, you can customize the time
of corresponding port to be open and closed, in order to achieve flicker effect.
3.11.2 Auto lubricate
After the port is configured, start time from opening the CypCut software. And
then close, after opening the corresponding output port during each interval time and
maintaining the setting output time.
3.11.3 Customize the output
Configure custom output port. The control buttons of custom port is displayed at
FSCUT2000 Laser Cutting Control System
53
the numerical control page of CypCut software. This custom port can choose the
control mode of self-locking or contactor.
3.11.4 Regional output
Regional output is mainly used for dust removal with machine. When laser starts,
cutting head moves to area A (as shown in figure above), and corresponding “output
port 12” of the area will be open; if trace moves from area A to area B, “output port
12” will be closed immediately, and “output port 15” will be open immediately.
3.12 Focus control
This function can be activated only when using BMC1205 motion control card,
mainly used for implementing electric adjustment in focus.
Pulse equivalent: Set the distance of movement focus corresponding to the
number of pulses per revolution of the drive.
Focus adjustment range: Set software limit and stroke of the focusing motion.
Return ORG direction: upward homing is negative direction, downward
homing is positive direction.
Coarse positioning speed: quickly find the speed of origin switch when homing.
Precise positioning speed: Slowly precise positioning speed after find the origin
switch.
Rollback distance: Reverse motion distance after completing precisely
positioning.
Focal position after homing: Define the focus scale corresponding to origin.
Jog speed: Speed of clicking motion focus.
Positioning speed: Empty traverse speed when focus moves.
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FSCUT2000 Laser Cutting Control System
3.13 Optical edge seeking
This function applies Omron E3Z-L61-type diffuse optical switch. The effective
detection range of the optical switch is 90 ~ 120mm. Automatic seeking edge can be
achieved by optical edge seeking, whose speed and precision is higher than
capacitance edge seeking. After click this function and configure the input port of
corresponding optical switch, you can use optical edge seeking in CypCut software.
3.14 Numerical control panel
BCP5045 numerical control panel can be activated in numerical control panel
FSCUT2000 Laser Cutting Control System
55
interface. When used in a stand-alone environment, CypCut software will adaptively
match the Mac address of BCP5045 numerical control panel, and automatically
connect the control. When BCP5045 is used in LAN environment, please enter
BCP5045 device ID number. BCP5045 is in total of 12 custom keys, which can be
configured as a control button of double exchange workbench or other custom PLC.
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FSCUT2000 Laser Cutting Control System
Chapter 4 Electrical System Debugging
4.1 Power test
Connect BCL3762 External IO Board and BMC1204 control card with C62-2
and C37-2 cables, and provide 24V power for BCL3762 External IO Board. Before
turn on system power, please confirm whether power connection is correct or not and
whether positive and negative polarity of power is short circuit or not.
Notes: Prohibit plugging BMC1204 card, C62 and C37 cable with electric
heating!
4.2 All the hardware signal test
Start computer and CypCut software. Click “file” in menu above→“Diagnosis”.
Please check in sequence positive/negative/origin switch of each axis, input
signal, output signal, DA signal, PWM signal and servo-enabled signal.
For machines of double shaft drive, count value of encoders of two axes can
be reset through 【reset】 button. Then send 1000 test campaign about the status of
each axis, and ensure feedback pulse value and sent pulse value of encoder is in
accord. Setting method can refer to Appendix 7.1 "Scan cut" introduction file for
more details.
4.3 Basic motion test
First, recommend setting servo driver parameters as conservative values. Also set
the parameters of CypCut as conservative values. Click “Layer” → “Global parameter”
on CypCut. Parameter setting is shown as below:
FSCUT2000 Laser Cutting Control System
57
Use pulse test function, test whether pulse equivalent of the system is set
correctly or not, click to test whether the direction and motion of each axis is normal
or not.
Dual-drive machines do not install the electric motor at first, with no-load
operation. Be sure to confirm the rotation direction and mechanical installation
method of electric motor is well, and then install the motor.
When it have been confirmed the limit origin signal is normal, make each axes of
the machine home origin and build machine coordinate system.
4.4 Cypcut basic functional test
Use control panel on the right of CypCut software to click manually, rise and fall
cutting head, switch gas, switch shutter, switch beam, laser on, and conduct each test
by the operation of changing fixed fire power etc. Confirm the system can normally
control laser, height controller, gas valve, etc.
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FSCUT2000 Laser Cutting Control System
Chapter 5 Motion effect optimization
5.1 Infer inertia ratio and machine characteristics
Machine inertia ratio is a key indicator we measure the machine characteristics.
Using Servo Tools of Friendess, we can very easily calculate the inertia ratio of the
machine for each axis. Servo Tools can be downloaded in http://downloads.fscut.com/.
As shown below:
When inertia ratio is less than 200 percent, the device is light loaded, and enables
high-speed cutting.
When inertia ratio is greater than 200% but less than 300 percent, the device is
medium loaded, lose some precision during high-speed cutting, and need to
appropriately reduce processing acceleration and FIR frequency.
When inertia ratio is greater than 300% but less than 500 percent, the device is
overloaded, unable to achieve high-speed cutting.
When inertia ratio is greater than 500%, there are serious design flaws, servo is
difficult to complete setting in a short time.
The maximum supported machine cutting speed, the maximum air shift speed,
and the maximum acceleration can also be simply calculated by Servo Tools. These
three parameters can be directly applied to control parameters in the software.
Experienced users can also accurately calculate the inertia ratio through testing
software coming with servo.
Notes: the servo parameters calculated by Servo Tool is only used for the closedloop card. Users of open-loop card, please set servo parameters based on position
mode.
FSCUT2000 Laser Cutting Control System
59
5.2 Servo gain adjustment
5.2.1 Basic requirement
First, debuggers should be familiar with servo and can use professional
servo software to debug servo. For example, Panasonic servo comes with
PANATERM testing software and Yaskawa servo comes with SigmaWin+ testing
software. This can simplify debugging.
5.2.2 Panasonic servo gain adjustment
STEP1: Open 【gain adjustment】 interface in PANATERM software. Open
【real time automatic adjustment】 function of target axis, to automatically estimate
inertia ratio.
STEP2: Rigidity is set as conservative value. For example, it can be set as level
13 first. Then click to move this high-speed axis with CypCut software. Observe
whether axis is with abnormal sound and vibration, etc. Raise rigidity slowly. When
the axis is with abnormal sound or vibration, level 1~2 should be declined to
guarantee system stability. The final level should not be level 10 and more than level
20. If it’s dual-drive shaft, it starts moving only after modify two pairs of drive shaft
parameters.
STEP3: After rigidity of X axis and Y axis is tested, set rigidity level as the same
level to guarantee response of two axes are the same. The smaller rigidity is standard.
For example, X axis is level 19 and Y axis is level 16. Finally, set X axis and Y axis as
level 16.
STEP4: Close 【real time automatic adjustment】 and save parameters.
5.2.3 Yaskawa servo gain adjustment
Yaskawa servo debugging is similar with the Panasonic. However, there is some
difference. The difference is as below:
 SigmaWin+ cannot be used to dual-drive axle ratio estimation, and advanced
auto-tuning. Inertia ratio calculation tool, Servo Tool can be downloaded from the
official website of Friendess to roughly calculate the inertia ratio for each axis.
Advanced users may also accurately calculate the inertia ratio, based on a change of
acceleration torque and acceleration time, by themselves.
 We suggest closing Pn140 model tracking function.
 We suggest closing Pn170 free adjustment function.
 Yaskawa servo does not introduce rigidity and can set the following
parameters based on Panasonic servo rigidity.
Pn102 position loop gain: Correspond to pr100 of Panasonic.
Pn100 speed loop gain: Correspond to pr101 of Panasonic.
Pn101 speed loop integral time constant: Correspond to pr102 of Panasonic.
Pn401 Torque filter time constant: Correspond to pr104 of Panasonic.
 The table is as below, and you should pay attention to unit and decimal point.
The unit of Yaskawa speed loop integral time constant, Pn101, is 0101 ms, while the
one of Panasonic is 0.1 millisecond.
FSCUT2000 Laser Cutting Control System
60
Rigid
ity
10
11
12
13
14
15
16
17
18
19
20
Pr1.00
Position
loop gain [0.1/s]
175
320
390
480
630
720
900
1080
1350
1620
2060
Pr1.01
Speed loop
gain [0.1Hz]
140
180
220
270
350
400
500
600
750
900
1150
Pr1.02
Speed loop
integral time
constant [0.1 ms]
400
310
250
210
160
140
120
110
90
80
70
Pr1.04*2
Torque
filter [0.01 ms]
200
126
103
84
65
57
45
38
30
25
20
5.2.4 DELTA servo debugging experience
Delta servo debugging can also refer to the rigidity table of Panasonic. The
reference method is shown as below:
The parameter P2-00 KPP is the equal of the position loop gain of Panasonic.
Though its unit is rad/s, actually, It's 1/s. For example, when the P2-00 KPP= 90, it’s
the same as Pr100=900 of the position loop gain of Panasonic.
FSCUT2000 Laser Cutting Control System
61
5.3 Motion Control parameter adjustment
5.3.1 Motion control parameter introduction
FSCUT2000 system mainly opens these four types of motion control parameters,
such as speed, acceleration, FIR frequency, corner and circular accuracy, to users to
adjust. Other sports-related parameters have been optimized internally without
needing user settings. The meanings of these four parameters are shown as below:
Name
Move speed
Move
acceleration
Max
acceleration
FIR frequency
Circle
precision
Corner
precision
Introduction
Maximum speed of air moving, can be directly fill with the
maximum move speed calculated by Servo Tools software s.
Maximum acceleration of air moving, can be directly fill with the
maximum move acceleration calculated by Servo Tools software s.
Maximum acceleration during processing, directly determines the
time of acceleration and deceleration of the turning movement
during cutting. Adjust by observing t the torque curve of servo.
Suppress filter frequency of machine vibration. The smaller the
value is, the more obvious the effect of suppressing the vibration is,
but which will make the time of acceleration and deceleration
longer.
Arc accuracy limit. The lower the value of the arc precision, the
more obvious the limit of arc speed is.
Fit with corner precision by NURBS curve. The lower the value is,
the closer the corner is closed to sharp corner, but the deceleration
will be more significant.
5.3.2 Adjust processing acceleration
The speed of high-clicking can be set as high as possible, such as 500mm / s.
When complete a click, moving distance is required to be long enough, in order to
ensure that speed can be accelerated to the setting value.
Observe the torque curve of click movement by the servo debugging software.
For example, if the maximum torque is less than 80%, appropriately increase the
processing acceleration; if the maximum torque is higher than 80%, appropriately
reduce the processing acceleration.
Adjust the acceleration, until the maximum torque nearly is 80%. Generally, the
processing acceleration withstood by lead screw is not more than 0.5G. Rack and
pinion generally is not more than 2G.
5.3.3 Adjust move acceleration
Directly fill the maximum acceleration calculated by ServoTool software, or
appropriately increase the move acceleration on the basis of processing acceleration,
for example, set as 1.5 to 2 times of the processing acceleration. It’s required that the
maximum torque of the servo is not more than 150%, and the mechanical structure
does not occure significant deformation and vibration under this acceleration. Screw
affordable air movement acceleration generally is not more than 0.5G. Rack and
pinion generally is not more than 2G.
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FSCUT2000 Laser Cutting Control System
5.3.4 Adjust FIR frequency
When you set up the FIR frequency parameter, you can cut a sample image. It’s
proposed that, at the beginning, turn down the laser power, and mark the plate.
Observe the accuracy of marking path. Cutting sample image includes various sized
small round, regular 6-gon, regular 12-gon, star, rectangular, etc. As shown below:
Adjust the FIR frequency as high as possible in the case of no affecting the
accuracy. It is required the corner does not generate waves when cutting a rectangle,
polygon and star. It can be set according to experienced value of the following table,
Or debug the FIR frequency within the upper and lower two ranges after determining
a processing acceleration. These two parameters, processing acceleration and FIR
frequency, must be matched, with never transferring one value quite large and another
value quit small among these two parameters.
Level
Processing
acceleration
(G)
FIR
frequency
(HZ)
1
2
3
4
5
6
7
8
9
10
0.1
0.2
0.3
0.4
0.5
0.6
0.8
1
1.5
2
3
3.5
4
5
5.5
6
6
6
7
8
FSCUT2000 Laser Cutting Control System
63
5.3.5 Set circle precision and corner precision
Generally, it’s not recommended that users modify the precision of arc and
corner. Under some special circumstances, you can fine tune these two parameters
within the range of default parameters.
If you are not satisfied with the accuracy of the arc, you can turn down the arc
precision parameters, at the same time the speed of process arc will be limited. The
smaller the value is, the more obvious the speed limit is. If you are not satisfied with
the accuracy of the corner, you can turn down the corner precision parameters, at the
same time the speed of turning the corner will decline. The smaller the value is, the
more obviously the speed declines. The higher the value is, the closer the corner will
be to a fillet.
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FSCUT2000 Laser Cutting Control System
Chapter 6 General Problems
6.1 “Motion control card initialization fails” pops up when
open Cypcut
1. “desktop” of computer→ click right in “my computer” →“attributes” →
“hardware” → “device manager”. Click “operation” → “Scan for hardware changes”. See
whether there is motion control card, as shown below: If BMC1204 motion control
card can be found in device manager, please try reopening Cypcut software
2. Observe the blinking state of 2 small lights on top of BMC1204. The
position of lights is shown as below:
LED Operation Indicator
JP2
JP1
BMC1204 Card
FSCUT2000 Laser Cutting Control System
65
The representative state of LED blinking is shown as below:
Blinking State
Meaning
Solution
1 blink 1 blink
running normally
normal
1 blink 2 blink
not available
/
1 blink 3 blink
unsupported USB
replace USB flash disk to
upgrade
1 blink 4 blink
1 blink 5 blink
FPGA BOOT data
transmission error
FPGA BOOT
initialization error
use USB flash disk to upgrade
use USB flash disk to upgrade
1 blink 6 blink
FPGA BOOT unable to
complete
use USB flash disk to upgrade
2 blink 3 blink
ARM upgrade failed
use USB flash disk to upgrade
2 blink 4 blink
file system formatting
error
back to repair
3. If LED is one flash and one flash (alternately flashes), which indicates BMC
1204 card is normal. Maybe PCI slot is bad contact. We suggest reinserting board
card or replacing PCI slot after computer switches off.
6.2 Pulse equivalent setting
The system defines that pulse equivalent is the command pulse count sent after
1mm movement.
The maximum pulse frequency of BMC1204 motion control card is 3Mpps.
Assume the maximum operating speed designed by the system is 1000mm / s. Then
the pulse equivalent for each axis should not exceed 3Mpps / 1000 = 3000 Pulse / mm.
Under the permitted circumstances, we suggest set the pulse equivalent in 1000 ~
2000 Pulse corresponding to per 1mm, and thus pulse sequence can be more
continuous. Please try not to set the pulse equivalent as 200Pulse / mm or less.
Set pulse equivalent of X axis and Y axis as the same as possible, which is
helpful to reduce truncation error calculated by the system.
6.3 How to use USB flash disk to upgrade BMC1204
After CypCut upgrades new functions, sometimes firm-wares of BMC 1204
card will be upgraded. In the case of interference, static, etc, firm-wares of control
card may be lost. Using USB flash disk to upgrade is a fast and effective solution.
The steps are shown as below:
STEP1: find a USB flash disk, formatting is FAT/FAT32.
STEP2: under CypCut installation directory (default: C:/ ProgramFiles
/Friendess/CypCut), there is a drivers directory. Copy BMC.AFM and BMC.FFM to
USB flash disk.
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FSCUT2000 Laser Cutting Control System
STEP3: Unplug USB flash disk and turn off PC. Open rear cover of PC,
insert USB flash disk into USB slot of BMC1204 card, and then turn on PC. At this
time, BMC1204 card will be upgraded automatically, in which LED will not blink.
After upgrade, the two LED will blink at the same time. It takes less than one
minute to upgrade.
STEP4: Unplug USB flash disk and turn off PC. And then turn on PC. Please pay
attention to don’t restart computer directly.
STEP5: After start PC, observe that whether LED is one flash and one flash
(alternately flashes). If it is, it means upgrade is successful.
6.4 Graphics processing is quite slow or pause
 In Cypcut, we use node mode to observe this graphic. If nodes are too many
and graphics consist of many micro-segments, please perform curve smoothing on
graphics and then process them.
 Check whether the unreasonable delay is set or not, or the unit is misread, for
example, set 200ms as 200s.
 If the Z-axis has pause during the movement of lifting and descending, please
check the program version of BCS100 height controller. If It’s BCS100 V2.0 height
controller, please make sure the program was upgraded to the version of V802 or later.
 Opening laser after blowing for a long time, please check the serial
communication of laser is available.
6.5 Corner burning
 If machine allows, improve FIR frequency and reduce time of acceleration and
deceleration.
 Properly increase turning precise parameters, and make high-speed smooth
transition in sharp corner with Bezier curve
 Modify the mapping way, processing the circle overcut by the example as
shown below.
 Modify power curve, turn down laser power when speed declines.
 Add cooling points on the corner, further processing after blow to cool for a
period with light off
6.6 Laser not emitting light
1. Check whether the laser setting is correct or not
① Determine correct laser configuration in the platform configuration tool (YLS
series of IPG has difference between German version and American version)
FSCUT2000 Laser Cutting Control System
67
② Determine whether serial port or Ethernet communications is applied and
communications port is configured correctly.
③ Determine whether the DA signal control is applied to control the peak
power, DA is selected correctly.
④ PWM-enabled and light-enabled is configured correctly.
2. Check the output signal of PWM and DA
① Modify the output value of DA and PWM in the interrogation window of
CypCut software (file—interrogation window). Use multi-meter to test whether DA of
BCL3762 terminal block and voltage of PWM output port is normal or not.
② If PWM output voltage is too low or the DA signal has no output, try to
replace another interface of PWM or DA.
③ If it’s hardware failure, please contact our technical support or apply for
repair.
3. Check connection
① Check the connection of PWM, serial cable and laser control signal lines.
② Make sure serial cable use a shielded cable. 2 pin and 3 pin need to be cross.
4. Check laser
① Use the matching software coming with laser to do self-checking and to check
light change, and to judge whether laser is working normally.
② In the case of serial communication, not allow to open multiple software to
communicate with lasers at one moment.
③ In the case of no serial port communication, you can click debug mode to
view the sent instructions and the response of the laser.
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FSCUT2000 Laser Cutting Control System
Chapter 7 Appendix
7.1 Scan cutting setting instructions
7.1.1 Function brief introduction
CypCut6.3.495 later version adds new functions: Scan cutting, also called fly
cutting. Scan cutting of regular array pattern (suit for sheet metal) and naturally
successive cutting of arc can be achieved by this function, thus greatly enhancing the
processing efficiency. Function buttons are shown in the area of the following figure.
7.1.2 Function description
1. Linearly same-direction-grouping scanning: After the rectangular array is
selected, set as linearly same-direction-grouping scanning. During the actual cutting
process, rectangular will be divided into four direction scanning movement. Move of
the middle section is not acceleration and deceleration shift, with just opening and
closing the light.
2. Naturally successive cutting of arc: After the circle array is selected, set as
naturally successive cutting of arc. Actual cutting is the same as connecting all circle
or arc with a straight line. There’s no acceleration and deceleration during processing,
with just opening and closing the light.
FSCUT2000 Laser Cutting Control System
69
7.1.3 Considerations
You must set the number and direction of encoder feedback pulses correctly
before using the scan cutting function! The setup method is shown as below:
1. Open the diagnostic window CypCut of software, and send 1000 pulses to the
X, Y-axis respectively in the "Pulse Test" module.
2. Judge whether it’s correct by encoder feedback value of "motion axis" and
polarity. (Note: Sending positive feedback 1000 should be 1000 but -1000)
3. If the pulse feedback transmitted forward is negative, enter “the platform
configuration tool - Machine page” to reverse the encoder corresponding to the
number of axis. (Note: Have to set synchronously the encoder feedback of the second
shaft and the third shaft in case of double-drive machine).
4. If the feedback is not 1000 after you send 1000 pulses, you need to adjust the
servo parameter, while Panasonic is Pr011, Yaskawa is Pn212, Delta is Pn146. Set it
as 1/4 of command pulses number per revolution. Panasonic A5, for example, it’s ok
set Pr011 (encoder feedback) as 1/4 of Pr008 (pulse number per revolution). Yaskawa
can be quickly set by installation wizard of SigmaWin + software.
7.2 Pitch compensation
7.2.1 Brief introduction of pitch compensation
Since the unevenness of screw, rack and other mechanical components exists,
there is often a bias the actual characteristic and nominal features. When high
precision is required, the actual deviations is required to be measured by a laser
interferometer and other precision instruments, and then be compensated by the
numerical control system, so as to achieve the purpose of reducing the deviation.
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FSCUT2000 Laser Cutting Control System
CypCut laser cutting system provides a complete and easy to use pitch
compensation function, can easily control the machine to run in accordance with the
requirements of the laser interferometer, and can directly read the data files outputted
by laser interferometers, such as Renishaw, API, Agilent, OptoDyne. Even in the
absence of laser interferometer supporting, reverse error compensation can also be set
separately.
7.2.2 Determine the machine origin
Before measurement error, we must first determine the machine origin. Screw
pitch compensation is compensated by the machine origin as a reference. If the origin
used by error measurement is different from the origin operating after machine
compensation, then the pitch compensation will become meaningless. The machine
homing origin can be set in the platform configuration tool of CypCut, as shown
below:
As long as conditions allow, be sure to select "Use Z signal", which will greatly
enhance the accuracy of homing origin. BMC1204 motion control card matched with
CypCut provides encoder input to each axis, to extremely ensure accuracy.
Please select the direction X and Y axes home origin based on machine actual
design. The direction of homing origin directly determines in which quadrant of the
coordinate system the machine will run. If you select the "negative direction" to
home origin, then the machine will run in the range of positive coordinates, otherwise
the machine will run in the range of negative coordinates.
If possible, please repeatedly home origin by CypCut, then measure the accuracy
FSCUT2000 Laser Cutting Control System
71
of homing origin by laser interferometer. Usually, the position of every homing origin
does not differ more than 5 microns.
7.2.3 Determine pulse equivalent
Due to the processing precision and assembly errors, often, there’s difference
between the pulse equivalent calculated by theory and the actual machine pulse
equivalent. The pulse equivalent can be accurately measured by laser interferometer.
Make the machine runs at a distance by transmitting a specified number of pulses
to the motor. For example, transmit the number of pulses which can make servo motor
run a circle, and then measure the distance between the two points by the
interferometer. It’s ok to fill the ted number of pulses and the distance in the platform
configuration tool.
The method of sending a fixed number of pulses in CypCut is to open the "File" "Diagnosis", select shaft as shown in the following figure window, input the pulse
number, and click "Send."
7.2.4 Error measurement
The error is measured by the interferometer, commonly known as "Open
interferometer." Generally, control the machine to stay for some time at an interval
distance by the numerical control system, and then laser interferometer can measure
the actual position of each point. The correspondence table of the theoretical position
and the actual position can be obtained after all location measurement has been
completed.
Most of the laser interferometers, such as Renishaw, must first set travel range,
test interval and time spent at each point before starting the test, for example, stay one
second every interval 30 mm. Laser interferometer decides whether to be measured by
determining the separation distance and dwell time.
Firstly, determine several parameters:
Travel range. The total travel range of preliminary measurement, generally is set
slightly smaller than the stroke of the machine design.
Measurement interval. Theoretically, the smaller the measurement interval is, the
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FSCUT2000 Laser Cutting Control System
more accurate the results is after the compensation; but the smaller the measurement
interval is, the more the point required to be measured is, and also the longer time it
takes. Recommended interval value is between 10 mm to 100 mm.
Dwell time. The minimum dwell time of Renishaw default is two seconds.
Make sure that the zero of laser interferometer and
machine is the same point.
During error measurement, make sure that the pitch
compensation function of platform configuration tool is
disabled, that is, "no compensation."
Take the following Renishaw interferometer as an example to introduce how to
measure the error using CypCut. Other lasers can be set by the reference.
Open Renishaw linear length measurment software, click "
the parameters.
" to start setting
The first anchor point is always 0, and final positioning point is the stroke range.
The interval value is the preceding measurement interval.
Click "
" to enter the next step.
FSCUT2000 Laser Cutting Control System
Click "
73
" to enter the next step. Input the information according to
requirement, and then click "
" to enter step 4.
Wherein, please set and record the minimum value of the stop cycle, which will
be used when setting parameters in CypCut. After completion, the laser interferometer
begin to collect data.
At the moment, Opens CypCut- "Numerical Control" - "light path adjustment"
screen, and find the following window:
Herein, the travel range is automatically read, please set as same as the setting
value of the interferometer, but pay attention to symbols. Input a negative value when
forward home origin, whereas input a positive value. If input an error value, the
system will prompt when you save.
Set the interval value as same as the value in interferometer. Otherwise, data may
be undetectable.
Please set dwell time slightly larger than the "minimal stop cycle" of the
interferometer, to ensure the interferometer can correctly identify each point required
to be measured.
Please ensure cycle number the same as "Measurement times" set in the
interferometer. Since CypCut only read once back and forth measurements, so the
first time data of the measured data of many times will be only read, when you import
the measured data of many times into CypCut.
Gap adjustment means during reverse movement, movement will be continued
along the original direction for 5mm, and then return 5mm, thereby eliminating the
mechanical interval. This value should not be greater than the value of the interval
value minus the tolerance window, otherwise the interferometer will mistakenly think
that this is a point required to be measured.
Click the "Generate interferometer positioning program", and then the
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FSCUT2000 Laser Cutting Control System
positioning program will be generated in the right window. Check the following
conditions are true and correct and click "Run" to start the measurement.
1. The measurement axis has return to the origin. Be sure to measure from the
origin
2. The interferometer is ready, and the parameters is matched with the
parameters set in CypCut.
After the test is complete, save the measurement results from the interferometer
software. The result is RTL format for Renishaw. Copy the files to a PC which
CypCut is running.
7.2.5 Import error data
The pitch compensation data files after obtained can be imported into CypCut.
CypCut can directly read files saved laser interferometer Renishaw, such as API,
Agilent, OptoDyne. If you are using the interferometer file which cannot be read by
CypCut, please contact us, we will try our best to solve it. The method of importing
error data is as below:
Open platform configuration tool, select the "complete pitch compensation" in
the "pitch compensation" of "Mechanism " Interface, as shown below:
And then click on "View compensation data", and pop up the following window.
FSCUT2000 Laser Cutting Control System
75
Click "Import X", which can import X-axis error data, and click "Import Y"
which can import Y axis error data. The imported results will be displayed in lists and
graphics after data completion.
If the position coordinates shown in the table is different with the direction of
homing origin, the compensation results will be invalid. Generally, when importing
data, CypCut will automatically determine the symbol of the position. If inconsistent,
please contact us to solve it, or adjust the measuring range as same as the stroke range
of the machine by modifying the measurement parameters of interferometer software,
and then import the data.
7.2.6 Manually input compensation data
1. Create an Excel spreadsheet, and save as xxx.xls or xxx.xlsx format. Data
input format is shown as below:
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FSCUT2000 Laser Cutting Control System
Position
0
50
100
150
200
250
300
350
Forward measured value
0.001
50.0021
100.0032
150.0043
200.0054
250.0065
300.0076
350.0087
Reverse measured value
-0.0005
-49.9932
-99.9859
-149.9786
-199.9713
-249.964
-299.9567
-349.9494
2. Open platform configuration of software – pitch compensation - Import above
documents
7.2.7 General problem solving
1. The compensation without changing before and after
If the data measured before and after compensation is almost no change, then it
maybe travel range is inconsistent, resulting in no valid data available for
compensation, that is, no compensation.
Please check the correspondence between the direction of homing origin and the
compensation data. The direction of homing origin is negative, and then the position
of compensation data should be positive; On the contrary, the direction of homing
origin is positive, and then the position of compensation data should be negative.
2. Error doubled after compensation
If it is found that the shape of the forward and reverse error curve is almost no
change after compensation, but the value almost doubled and the distance between the
two curves is also doubled (That is, reverse interval), it is likely that the sign of error
value is reversed. In this case, click the "error value inversion", which can make
compensation accuracy is greatly improved.
As shown below, it is a typical doubled case after compensation.
After compensation, the maximum error is 0.12 mm, reverse interval is 0.022
mm, and the curve shape is no change.
FSCUT2000 Laser Cutting Control System
77
After compensation, the maximum error is 0.2 mm, reverse interval is 0.048 mm,
and the curve shape is no change.
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FSCUT2000 Laser Cutting Control System
The reason for the problem is that the error data file provided to CypCut does
not contain the measured value, while only contain the error between the measured
value and the theoretical value. And the error may be found by the measured value
subtracting the theoretical value, or the theoretical value subtracting the measured
value, leading to import data which has two possibilities.
The pos file formats generated by API XD Laser Interferometer, as well as the
lin file format generated by light moving OptoDyne, contains both the theoretical
value and the measured value. So the question of error sign when reading would not
arise.
3. Reverse interval doubled after compensation
If it’s found that the pros and cons have been improved after compensation, but
the effect of improvement is not obvious, and the reverse interval has increased even
with doubling trend, it is likely that the forward data has been compensated to the
reverse, and the reverse data has been compensated to the forward. At this moment,
please click the "exchange of pros and cons" to make the positive and negative data
(that is, red and green curves) reversed.
When the data sign tested by interferometer is inconsistent with the actual stroke
range sign of machine tool, this situation most likely happens. The positive direction
determined by interferometer is the direction of coordinate increasing, opposite to the
FSCUT2000 Laser Cutting Control System
79
direction of the machine coordinate increasing. CypCut has automatically handled this
situation as much as possible, but it still cannot guarantee that all cases can be handled
automatically.
4. The positive and negative curve is symmetrical after compensating.
If it’s found that positive and negative curves symmetrically change after
compensation, the most likely reason is that the sign of forward error and reverse
error is opposite, one of which is correct, and the other is wrong. This condition is
considered to be very rare. In order to reduce the difficulty of customers
understanding, CypCut has blocked the button which deals with this situation. If this
happens to you, please manually make the error of forward or reverse reversed before
importing, and then import. Or contact us to help solve.
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